Embossing roll



June 27, 1967 T. c. CATLIN 3,327,369

EMBOSSING ROLL Filed 061;. 11, 1965 2 Sheets-Sheet 1 1 INVENTOR THOMAS C. CATLIN M/I/M AT TORNEY T. C. CATLIN EMBOSSING ROLL June 27, 1967 2 Sheets-Sheet 2 Filed Oct. 11, 1965 iNVENTOR THOMA S C. C ATLIN Zfl/M ATTORNEY r United States Patent 3,327,369 EMBOSSING ROLL Thomas C. Catlin, Neenah, Wis, assignor to Tuttle Press, Appleton, Wis., a corporation of Wisconsin Filed Oct. 11, 1965, Ser. No. 494,708 1 Claim. (Cl. 29-119) This invention relates to embossing and it more specifically resides in an embossing roll having a stiff roll body to withstand embossing pressures and an embossing pattern fastened to a woven sleeve that can readily be mounted on or removed from the roll body.

The usual embossing roll for imprinting raised designs in papers, foils and other sheet materials take the form of heavy steel in which the pattern to be embossed into the sheet material is an integral part of the roll, for example the pattern may be engraved in the roll. Such a roll is expensive to produce, and is not practical unless large runs of the pattern are to be made.

The present invention introduces a relatively inexpensive means of producing an embossing roll, making it economically feasible to have short production runs of both complex and simple patterns. Also, a paper converter can then stock a variety of embossing patterns, and can easily change from pattern to pattern to give a greater variation in its embossed goods. Individual embossing treatment can also be given to the products of customers who have smaller orders, or who have need for a variety of designs in the production of a complete line of goods. For example, gift wrap paper can now be made with several embossing patterns in a. single consumer package, or for a set of cocktail napkins each napkin of the set may be both embossed and printed with an individually distinctive pattern.

In a typical embodiment of the invention a sturdy roll body with a plain, cylindrical surface has an open mesh, woven sleeve fixed thereon, which sleeve in turn mounts a male embossing pattern. The pattern is thin metal stock which can be produced by electrotype, or photo methods known to the printers arts. This pattern is fixed to the open mesh sleeve by soldering through the mesh, and then the sleeve is fitted tightly around the roll body to produce the completed embossing roll. Such sleeve can be readily removed, and other patterns installed at low cost.

It is an object of this invention to provide an embossing roll for various sheet materials that can be readily produced at low cost.

It is another object of this invention to provide a construction for embossing rolls in which one roll body can be used with a variety of interchangeable patterns that can be easily applied to and removed from the roll body.

It is another object to provide an inexpensive emboss ing roll which imprints a clear and sharp image to the material being embossed.

It is a still further object to provide an inexpensive embossing roll that may include highly intricate patterns.

The foregoing and other objects and advantages of this invention will appear from the following description. In the description reference is made to the accompanying drawings which form a part hereof, and the drawings and description show by way of illustration and not of limitation specific embodiments in which the invention may be practiced. The description is to enable one skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized without departing from the invention. For a scope of the invention reference is made to the claim at the end of the specification.

In the drawings:

FIG. 1 is a view in perspective of an embossing roll embodying the invention together with a mating back-up roll,

FIG. 2 is a view of a thin embossing pattern that is affixed to the roll,

FIG. 3 is a view in section, on an enlarged scale, of the embossing roll of FIG. 1,

FIG. 4 is a view of a second embossing roll embodying the invention with part of a woven sleeve broken away to disclose end construction of the roll,

FIG. 5 is an end view of the roll of FIG. 4 without a sleeve, and

FIG. 6 is a fragmentary view in section, on an enlarged scale, of the roll of FIG. 4.

Referring now to FIG. 1, there is shown an embossing roll 1 that works against a mate roll 2, and for the embossing operation the rolls are turned in the directions shown and a web of material is fed through the nip of the rolls, as in usual practice. The roll 1 has a rigid, nondefiectable body 3 that can conveniently be of steel to withstand embossing pressures without yielding and detrimentally affecting the embossing. The outer surface of the roll body 3 is cylindrical and uniformly smooth, so that no undue expense is incurred in the provision of the roll body 3.

Fitting tightly about the roll body 3 is a woven metal screen which forms an open mesh jacket-like sleeve 4. A seam 5 in the sleeve 4 is formed with the sleeve 4 in place, and the sleeve 4 is spot tacked to the roll body 3 at a plurality of points 6 to restrain it from twisting or shifting about the body 3. An embossing pattern 7 of thin metal is attached to the woven sleeve 4, and it rises above the sleeve surface for indenting a paper web, or the like, in an embossing operation. The mate roll 2 has a resilient surface that is pressed against the embossing roll 1, by proper adjustment of the rolls, and functions as a back-up roll in usual fashion.

The embossing pattern 7 is very thin, and one convenient manner of forming is by the electrotype process of the printers art. Other photographic-electrolytic deposition processes can be employed, and for simple patterns thin shim stock can be fabricated, or an engraving machine can be used to form the pattern from thin sheet stock. The material of the pattern 7 should preferably be one that readily lends itself to silver soldering, and the pattern 7 is affixed to the sleeve 4 by soldering from the rear of the pattern. FIG. 3 shows the manner of attachment, and as shown therein the pattern 7 is dished with a concave rear side to form a trough that is filled with solder 8. When the pattern 7 is then placed upon the woven sleeve 4 and heat is applied the solder 8 flows to unite the pattern 7 with the sleeve 4. The dished configuration for the pattern 7 is accomplished within the skill of the electrotype art. The front surface and side edges of the pattern 7 are kept free of solder, so that the definition of the pattern imprinted in a web is not impaired. Hence, it is desirable to have an open mesh for the sleeve 4 to allow a heavy application of solder for firmly attaching the pattern that flows into the interstices of the open mesh. The thickness of the pattern 7 can be kept minimal, so that it will readily flex to conform with the roll body 3. A pattern 7 with solder on its underside can also be employed for attachment on a non-foraminous sleeve, but then much greater care must be exercised in restricting the solder flow, unless the fidelity of the embossment of the pattern is not particularly critical.

The materials for the pattern 7 and sleeve 4 should be such as to have a high bonding strength with the solder, or brazing medium employed. High strength silver solders are preferred, and copper base metals for the pattern 7 and sleeve 4 are recommended. A wide variety of metals bond with silver solder, however, and the invention is not confined to any particular selection. The sleeve 4 can be a woven screen of about twenty mesh or greater, and stainless steels, or coated screening, as well as uncoated copper alloys may satisfactorily be employed. For long life the pattern 7 can be plated with a hard, Wear resistant metal.

With the pattern 7 attached to the sleeve 4, the sleeve 4 is wrapped about the roll body 3 and a seam 5 is formed which can conveniently be a silver solder seam. The sleeve 4 is also spot tacked at points 6 to the roll body to restrain it from shifting, and these points of tacking can be a heavy application of solder outward of the edge margins of the web to be embossed. After use of the finished embossing roll 1, the sleeve 4 can be freed by melting and removing the tacking solder, and can then be slid off the roll body 3 for storage and future use. A variety of patterns can be employed on one roll body 3, and the cost of each is much. less, than for a conventional embossing roll.

An alternative means of attachment for the pattern 7 is shown in FIGS. 46. A metal woven sleeve 9, which is formed into a cylindrical jacket before placement upon a body roll 10, has a seam 11 running on a diagonal. The warp and weft wires comprising the sleeve 9 are likewise on the bias to the axial direction of the roll body, so that if an endwise pull. is applied to the cylindrical sleeve 9 it will readily shrink in diameter.

Each end of the body roll 10 has an end ring 12 that is of the same diameter as the roll 11 and is positioned in coaxial relation therewith. Each end ring 12 has a step 13, and the ends of the sleeve 9 encircle the end rings 12 and are clamped over the steps 13 by circular clamps 14. Each clamp 14 has a threaded tightening shaft 15 which can be turned to constrict the clamp, so that the ends of the sleeve 9 are tightly held by the end rings 12. With the sleeve 9 clamped to the end rings 12, the end rings 12 are moved axially outward by sets of tightening bolts 16 that are threaded in the rings 12 and have ends working against the end faces of the body roll 10. The embossing pattern 7 of FIGS. 46 is attached to the sleeve 9 before being slid onto the roll 10 in the same manner as in the embodiment of FIGS. 1-3.

The invention is useful for embossing all types of webs. Gift wrap paper, napkins, doilies, place mats, foils and laminates are a few of the variety of sheet material that may be treated. The embossment of a stiffer paper, such as letterhead paper, is also contemplated. For lightweight papers, such as a twenty-five pound 24 x 36500 gift wrap paper the pattern 7 can be five thousandth of an inch thick, and a well defined, visible embossment is achieved in which the mesh of the screen is not a part of the pattern. By setting the rolls 1, 2 for greater pressure, the weave of the screen can also be made a background for the principal pattern 7. The mate roll 2 should have a proper plastic, 'or resilient character, and for the example cited a to plastometer cover for the mate roll 2 is satisfactory.

Thus, the invention provides an inexpensive embossing roll which greatly facilitates the use of embossing in a greater variety of patterns Where heretofore a uniform pattern had to be continuously used, or embossing was not feasible.

I claim:

In an embossing roll the combination comprising: a roll body having a substantially plain surface; an end ring at each end of the body that is movable axially outward with respect to the roll body; tightening means associated with each end ring and operable on said end ring to move said end ring axially outward with respect to said roll body; a woven metal sleeve encircling said roll body having the warp and weft threads on a bias to the axial direction of the roll body, the ends of said sleeve being, fastened to said end rings for axial stretch thereof upon outward movement of the end rings; and a thin metal embossing pattern mounted on said sleeve that upstands therefrom and which is attached to the sleeve by solder at the underside of the pattern which runs into the mesh of the woven metal sleeve.

References Cited UNITED STATES PATENTS 1,110,397 9/1914 Martini 29-1l9 1,362,598 12/1920 Brown l()l23 1,657,889 1/1928 Manns 10l32 1,855,212 4/1932 Adsit et al 101224 X 2,149,649 3/1939 Webb 29-121 ROBERT E. PULPREY, Primary Examiner.

W. F. MCCARTHY, Assistant Examiner. 

